Modular building capable of being readily assembled

ABSTRACT

A modular building capable of being readily assembled and disassembled comprising rectangular base and roof frames each formed by two longitudinal beams and two lateral beams, the roof frame having a smaller periphery than the base frame. Four columns extend between corners of the base and roof frames, these columns being set back within the periphery of the base frame while having a periphery matching that of the roof frame. The building includes a floor panel having an outer periphery matching the periphery of the roof frame and being dimensioned to rest on inner edge portions of the base frame beams, a roof panel for resting on the roof frame and having an outer periphery at least as large as that of the base frame, and side and end wall panels dimensioned to fit between the base frame beams and the roof panel.

FIELD OF THE INVENTION

The present invention relates to a modular building, and provides aseries of components which can readily be assembled into a temporarystructure, and readily disassembled and moved.

BACKGROUND OF THE INVENTION

Building sites often have need of a temporary building which can serveas an office or as shelter for workers. Often such a building is in theform of a trailer. It is also known to provide buildings in modular,knock-down form.

SUMMARY OF THE INVENTION

The present invention provides a temporary building of modular typewhich can be delivered to a site, such as a building site, indisassembled, generally flat form, and in which the components canreadily be bolted together to provide a somewhat insulated andweather-proof structure. The building can be, generally from 20 to 60feet in length, and generally from 8 to 14 feet in width, the buildingsbeing connectable to other building to provide larger buildings asneeded or desired.

In accordance with the present invention, a modular building capable ofbeing readily assembled and disassembled comprises, a rectangular baseframe formed by two longitudinal base beams and two lateral base beamsconnected at their ends, so that said base beams define a firstrectangular periphery; a rectangular roof frame formed of twolongitudinal roof beams and two lateral roof beams connected at theirends so that said roof beams define a second rectangular periphery whichis less in width and length than said first rectangular periphery; fourcolumns adapted to extend between corners of the base and roof framesand attachable thereto, said four columns, when positioned, having outersurfaces defining a rectangular outer periphery which substantiallymatches said second rectangular periphery of the roof frame, saidcolumns being set back within the corners of said the first rectangularperiphery of the base frame; a floor panel having an outer peripherysubstantially matching said second periphery, said floor panel beingdimensioned to rest on inner edge portions of the base beams; a roofpanel for resting on the roof frame and having an outer periphery atleast as large in length and width as said first rectangular periphery;and side and end wall panels dimensioned to fit between said base beamsand said roof panel with said wall panels resting on outer edge portionsof said base beams, said wall panels enclosing outer peripheries both ofsaid four columns and of the roof frame.

Preferably, the base beams and roof beams are I beams. Also, the columnsare preferably I beams having upper and lower end plates at theirrespective upper and lower ends, these end plates having apertures forbolting to apertures in the roof and base beams.

The lower end plates of the columns preferably may each have fourrectangularly positioned bolt apertures, an outer three of theseapertures being suitable for bolting to apertures in inner edge portionsof the base beams at a respective corner. The base beams also have areinforcing corner element attached to the inside of each corner of thebase frame, which reinforcing corner element has an additional apertureend positioned to be bolted to the fourth, inside, aperture of the lowerend plate of a column. The reinforcing corner element for each corner ofthe base frame may be in the form of a tube having sides welded to innersides of the base beams and having an upper end plate provided with saidadditional aperture. The corner elements may extend below the base beamsto provide legs for resting on the ground.

The roof frame may have apertured lifting lugs fixed to the top thereof,each lug positioned above one of said columns, the roof panel havingapertures to accommodate the lifting lugs.

The roof beams may each have, attached thereto in parallel relationship,an additional elongated roof member, such as a channel member, whichprovides flanges at the second rectangular periphery, so that theseflanges provide locating means for the side and end wall panels.Similarly, the base beams may each have, attached thereto in parallelrelationship, an additional elongated base member having an upstandingflange suitable for locating the outer periphery of the floor panel onthe inside of the flange, and also suitable for locating lower edgemargins of the wall panels on the outside of the flange.

In longer versions of the building, the base frame and roof frame mayeach have one or more additional, intermediate lateral members whichmeet the longitudinal members at intermediate areas. These intermediateareas of the base and roof frames are connectable by additionalintermediate columns which have bolt connections to the base and roofbeams. In this construction, the lifting lugs are preferably provided atthe upper ends of the intermediate columns, rather than at the cornersof the roof frame.

Furthermore, both the base frame and the roof frame may have one or moreadditional longitudinal beams fixed at their ends to the lateral baseand roof beams and to the lateral intermediate beams.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will now be described by way ofexample with reference to the accompanying drawings, in which;

FIG. 1 is an isometric view of a first building in accordance with oneembodiment of the present invention, before the addition of its roofpanel;

FIG. 2 is a similar view but with the frames disassembled, and in whichthe floor panel covers the base frame and a roof panel covers the roofframe;

FIG. 3 is a partially assembled view of the base frame and roof frame ofone embodiment of the present invention, and also showing columnsattached to the roof frame;

FIG. 3 a is a detail view of the part C of FIG. 3, showing the cornerconstruction of the base frame;

FIG. 3 b is a detail plan view of a corner of the base frame;

FIG. 3 c is a detailed view of the portion D of FIG. 3, showing thelower end of a column;

FIG. 4 is an isometric view of the base and roof frames and the columnsassembled together, and also shows lifting lugs attached to the roofframe;

FIG. 4 a is a detailed view of the portion A of FIG. 4, showing theattachment of the lower end of a column to a corner of the base frame;

FIG. 4 b is a detailed view of the portion B of FIG. 4, showing thelifting lug connected to the corner of the roof frame;

FIG. 5 shows a cross-sectional view through a completed building;

FIG. 5 a is a detailed view of the connection of the lower portion ofthe enhanced wall of one embodiment of the present invention;

FIG. 5 b is a detailed view of the connection of the upper portion ofthe enhanced wall of one embodiment of the present invention;

FIG. 6 is an isometric view of the base and roof frames of a secondembodiment of the building, which is longer and which has additionalbeams and columns;

FIG. 6 a is a detail view of the lifting lug as positioned in the FIG. 6construction, and

FIG. 6 b is a detailed top plan view of a lifting lug as positioned insaid second embodiment;

FIG. 7 a is a cross-sectional view, of an enhanced end wall panelinstalled on an end wall in one embodiment of the present inventionviewed from within the building unit looking toward the enhanced endwall panel;

FIG. 7 b is a cross-sectional view of an enhanced wall panel of oneembodiment of the present invention;

FIG. 7 c is a detail cross-sectional view of the lower end portion C ofthe enhanced wall panel illustrated FIG. 7 b;

FIG. 7 d is a detail cross-sectional view of the mid-portion D of theenhanced wall panel illustrated FIG. 7 b;

FIG. 7 e is a detail cross-sectional view of the upper end portion B ofthe enhanced wall panel illustrated FIG. 7 b;

FIG. 8 a is an illustration of the attachment of two buildings in oneembodiment of the present invention;

FIG. 8 b is a detailed view of the lower connection element for theattachment of two buildings in one embodiment of the present invention;

FIG. 8 c is a is a detailed view of the upper connection element for theattachment of two buildings in one embodiment of the present invention;

FIG. 8 d is a perspective view of the connection element illustrated inFIGS. 8 b and 8 c.

DETAILED DESCRIPTION

FIG. 1 shows the first embodiment 10 of a modular building, with theroof panel removed. The building has a base frame 12, a roof frame 14connected to the base frame by columns which are not shown in this view,being concealed by inner corner plates 16. The building has a floorpanel 18, front and back sidewall panels 20 and 22, and end wall panels24. In one embodiment of the present invention, the front wall panel 20has an opening for a door D and a window W, and one end wall panel has,for example, another window opening W. Lifting lugs 26 are shown at thecorners of the roof frame 14.

FIG. 2 shows a disassembled view of the same parts, with the addition ofroof panel 28 which rests on roof frame 14. This view also shows columns30 at the ends of the side wall panels 20 and 22.

FIG. 3 shows a partially disassembled view of the base frame 12, theroof frame 14, and the four columns 30 which connect corners of the baseframe 12 to the corners of the roof frame 14. FIG. 4 shows an isometricview of these frames as assembled, and also shows the lifting lugs 26.

As shown in FIGS. 3 and 4, the base frame comprises two longitudinal Ibeams 12 a and two lateral I beams 12 b connected together at their endsto form a frame having a first rectangular periphery. The corners areformed by having the upper and lower flanges of the lateral beams 12 bcut back and welded at their ends to the sides of end portions of thelongitudinal beams 12 a while the webs of the beams 12 b are welded attheir ends to the web of the beam 12 a. The outermost parts of the endsof the longitudinal beams 12 a are closed by small end plates 32, alsoshown in FIG. 3A, 4, 5 and 5 a.

As shown in FIG. 4, The roof frame 14 is formed in generally similarmanner, with longitudinal beams 14 a having end portions welded to endsof the flanges and webs of lateral beams 14 b, and having an outermostportion of the ends of the longitudinal beams 14 a closed by small endplates 34, also shown in FIG. 4 b, 5 and 5 b. The beams 14 a and 14 bdefine a rectangular periphery which is slightly smaller in both widthand length than the first periphery of the base frame.

As shown in FIGS. 3 and 4, the columns 30 are connected at upper ends tothe corners of the roof frame 14, and have outer surfaces defining thesame periphery as the roof frame. The connection is made as shown inFIG. 5 by having the upper end of column 30 closed by a rectangularplate 30 a welded perpendicularly across its end, the plate 30 a havingfour apertures which can be bolted to apertures in the underside of anend portion of a beam 14 a.

As stated, the periphery of the roof frame 14 and of the columns is lessthan that of the base frame; in effect the roof frame and columns areset back about ½ the width of the base beams 12 a and 12 b. This meansthat the columns 30 cannot be bolted to the base frame in quite the samemanner as they are to the roof frame. Details of a corner of the baseframe are shown in FIGS. 3 a and 3 b, and the actual attachment betweena column and a corner of the base frame is shown in FIG. 4 a.

As seen in FIGS. 3 a, 3 b and 5, the inside of a corner formed by thelongitudinal and lateral base beams 12 a and 12 b is provided with areinforcing corner element 36 preferably in the form of a square tubehaving two sides welded to surfaces or edges of the beams 12 a and 12 b.As shown in FIGS. 3 a and 3 b, the upper end of this tube 36 ispreferably closed by transverse plate 38 having an aperture 38 a, andthe underside of this plate 38 has preferably welded to it a nut 38 bfor receiving a bolt 38 h passing through the aperture 38 a. As will beseen in FIG. 3 b, this aperture 38 a is one of four apertures providedat the corner of the base frame, the other three apertures 40 beingprovided in inner flanges of the beams 12 a and 12 b. These threeapertures 40 and the additional aperture 38 a are rectangularlypositioned, specifically being located as at the corners of a square.

FIG. 3 c shows the formation at the lower end of a column 30, and showsthe lower end plate 30 b, similar to plate 30 a, which closes the lowerend of the column 30, and which has four apertures for bolts which canpass through the apertures 38 a and 40 to connect the column to thecorner of the base frame. Two of these bolts 42 are shown in FIG. 4 a.As also seen in FIG. 3 a, the upper surface of plate 38 is level withthe upper surfaces of the beams 12 a and 12 b.

FIG. 4 b shows details of a lifting lug 26, one of four provided at thecorners of the roof frame. This consists of a short square tube 46having its lower end welded to the top of roof beams 14 a, and having aplate 48 with its sides welded to opposite inside corners of the tube 46so as to extend diagonally across the tube. The plate 48 is providedwith an aperture 48 a which is suitable for engagement by a hook, sothat the parts provide a lifting lug whereby during assembly ordisassembly of the building, the roof may be lifted as needed, and oncefully assembled, the building can be lifted by a crane attached to thefour lugs.

FIG. 5 a shows some additional members which help to locate the floorand wall panels and which are fixed in parallel relationship to thebeams of the base and roof frames. These include angle members 50 havinga lower flange 50 a welded to the inner side portions of the base beams12 a and 12 b, and, as illustrated in FIG. 5 b, channel members 52welded to outer or lower edge portions of the roof frame beams 14 a and14 b. The members 50 and 52 terminate at the columns 30. The anglemember 50 is positioned so that its outer flange 50 b has the sameperiphery as the roof frame and the columns 30. The channel member 52has a periphery matching that of the roof frame and the columns.

As also shown in FIG. 5 a, inner surfaces of flanges 50 b of anglemembers 50 locate the outer edges of the floor panel 18, and their outersurfaces locate the lower edges of wall panels provide means forsecuring these panels to the base frame. Floor panel 18 has notches cutin its corners to accommodate the columns 30, as shown in FIG. 2. Asillustrated in FIG. 5 b, the outer surfaces of the channel members 52locate the upper margins of the wall panels and provide means forsecuring these panels to the roof frame.

As will be seen in FIG. 5 and FIG. 5 a, lower edges of the wall panelspreferably rest on outer portions of the base beams 12 a and 12 b. Theamount by which the columns, and roof frame, are set back from theperiphery of the base frame is typically 3 inches. In the preferredembodiment the wall panels 20, 22 and 24 are each two inches thick,while the floor and roof panels 18 and 28 are three inches thick.Preferably both types of panels are formed of closed cell insulatingfoam, encased on inner and outer sides by sheet steel. Suitable panelmaterial is sold under the trademark “Accuwall” by Vicwest of Oakville,Ontario, Canada. When the wall panels have been put in place, andattached to the members 50 and 52, the junctions between the panels canbe concealed by corner plates 16 as shown in FIG. 1.

In one embodiment of the present invention, enhanced wall panels may beutilized as illustrated in FIGS. 7 a, 7 b, 7 c, 7 d and 7 e. Asillustrated in FIGS. 7 a, 7 b, 7 c, 7 d and 7 e, preferably having oneor more sheets 111 of closed cell insulating foam 112, encased on theinner side and outer side by sheet steel 114 as previously described,and additionally having a preferably aluminum or steel sheet 122securely attached to and covering a substantial portion of the inwardsurface thereof (the aluminum sheet being preferably screwed orotherwise securely fastened to the sheet steel in a manner known to aperson skilled in the art). In one embodiment, an inverted “U” shapedlength 134 of extruded aluminum is screwed or otherwise securelyfastened along the top of the enhanced wall panel as illustrated in FIG.7 e, and a “J” shaped length 120 of extruded aluminum is screwed orotherwise securely fastened along the bottom of the enhanced wall panelas illustrated in FIG. 7 c, the upper inverted “U” shaped length 134 ofextruded aluminum having recesses 132 or grooves therein along thelength thereof to receive and secure lengths of rubber or otherweatherproofing materials in a manner known to a person skilled in theart. Additionally, upper inverted “U” shaped length 134 of extrudedaluminum preferably having a recess 130 or groove therein along thelength thereof to receive and secure lengths of rubber or otherweatherproofing materials in a manner known to a person skilled in theart so that when the enhanced wall panel is installed, the lengths ofrubber or other weatherproofing materials will provide a water andweather-tight seal between the inverted “U” shaped length 134 ofextruded aluminum and the underside of the roof panel 28 as illustratedin FIGS. 5 and 5 b. Similarly, the lower “J” shaped length 120 ofextruded aluminum preferably has recesses 116 or grooves therein alongthe length thereof to receive and secure lengths of rubber or otherweatherproofing materials in a manner known to a person skilled in theart. Additionally, lower “J” shaped length 120 of extruded aluminumpreferably has a recess 118 or groove therein along the length thereofto receive and secure lengths of rubber or other weatherproofingmaterials in a manner known to a person skilled in the art so that whenthe enhanced wall panel is installed, the lengths of rubber or otherweatherproofing materials will provide a water and weather-tight sealbetween the “J” shaped length 120 of extruded aluminum and angle surface50 b. The enhanced wall panel may be installed by passing screws throughthe channel member 52 into the enhanced wall panel as illustrated inFIG. 5B, and through the angle members 50 and the lower “J” shapedlength 120 of extruded aluminum as illustrated in FIG. 5A or in suchother manner known to a person skilled in the art. In a furtherembodiment of the present invention, as illustrated in FIGS. 7 a, 7 band 7 d, a length of aluminum 108, preferably in square tubular form, iswelded or otherwise securely fastened to the inward-facing surface ofthe aluminum sheet, to thereby increase the structural integrity of theenhanced wall panel, the aluminum tube being securely fastened at bothends, to the vertical columns 30 in a manner known to a person skilledin the art.

The interiors of the wall panels can be provided with bus bars 60, fuseboxes 62, etc. as shown in FIG. 1, for bringing electrical supplies intothe building.

FIG. 6 shows the framework of a similar modular building which differsfrom that so far described in being longer, having a length of 40 feetas compared to a typical length of 20 feet for the first embodiment. Thebase frame 112 has outer longitudinal I beams 112 a and lateral outer Ibeams 112 b connected at their ends in similar manner to the base beamsof the first embodiment. Here, however, two intermediate lateral beams113 are provided, having ends welded to the longitudinal beams 112.Also, there are provided two intermediate longitudinal beams 116 whichhaving separate segments 116 a, 116 b, and 116 c, these segments beingwelded respectively between a first end lateral beam 112 b and a firstintermediate lateral beam 113, between the first intermediate beam 113and the second intermediate beam 113, and between the latter beam andthe second end lateral beam 112 b. The lateral beams 113 have the samecross-sectional dimensions as the beams 112 a and 112 b, while theintermediate longitudinal beams 116 are of lesser height than the otherbeams but have their upper surfaces co-planar therewith so as to givelevel support for a floor panel.

In this embodiment, the roof frame 114 has longitudinal beams 114 a and114 b, and also has two intermediate lateral beams 118 which overlie thebeams 113. The roof panel also has an additional, central longitudinalintermediate beam 120, having three segments 120 a, 120 b and 120 cextending respectively between a first end beam 114 b and a firstlateral beam 118, between this beam 118 and the second beam 118, andbetween the second beam 118 and the second end beam 114 b. Again, thelateral beams 118 have the same cross-sectional dimensions as the outerbeams 114 a and 114 b, while the intermediate longitudinal beam 120 hasa less depth but has a top co-planar with the other beams to givesupport for the roof panel.

As with columns 130, the columns 131 are set back from the outerperiphery of the base frame and have the same periphery as the cornercolumns. At each junction of base beam 112 a and each intermediate basebeam 113 each of these two connected beams provides two apertures forattachment to four bolts securing the base plate of an intermediatecolumn 131 to the junction. The base plates of the columns are similarto that shown in FIG. 3 c, having a square arrangement of aperturesmatching the apertures in beams 112 a and 113. At upper ends of theseintermediate columns 131 the roof beams 114 a provide apertures forconnection to top plates of the columns, adjacent the attachment pointsof intermediate beams 118.

FIGS. 6 a and 6 b show details of the lifting lugs 126 for thisembodiment. The lugs are the same as those of the first embodiment, butare attached to portions of the roof beams 114 a which overlie theintermediate columns.

As previously described, two or more building units may be connectedtogether to form larger building units, such as, for example, asillustrated in FIG. 8 a, where a first building unit 150 is connected toa second building unit 152, by way of connection elements 160 and 162 asmore fully hereinafter described. In the preferred embodiment, asillustrated in FIGS. 8 b and 8 c, a lower connection element 160 and anidentical upper connection element 166 having bolt holes 162 therethrough as illustrated in FIG. 8 d, may be securely fastened by way ofbolts (not shown) to adjacent columns 130 of the adjacent building unit,which columns 130 have corresponding bolt holes 164 there through inalignment with the connection element bolt holes 162, so that when thebuilding units are positioned adjacent one another, lower connectionelements 160 and identical upper connection elements 166 may be boltedto adjacent columns 130 of the adjacent building units to therebytemporarily and securely connect the adjacent building units to former alarger building unit, it being understood that alternative methods maybe utilized, as would be known to a person skilled in the art, totemporarily and securely connect the adjacent building units to formerlarger building unit.

The present invention has been described herein with regard to preferredembodiments. However, it will be obvious to persons skilled in the artthat a number of variations and modifications can be made withoutdeparting from the scope of the invention as described herein.

1. A modular building capable of being readily assembled anddisassembled comprising: a. a rectangular base frame formed by twolongitudinal base beams and two lateral base beams connected at theirends, so that said base beams define a first rectangular periphery; b. arectangular roof frame formed of two longitudinal roof beams and twolateral roof beams connected at their ends so that said roof beamsdefine a second rectangular periphery which is less in width and lengththan said first rectangular periphery; c. four columns adapted to extendbetween corners of the base and roof frames and attachable thereto, saidfour columns, when positioned, having outer surfaces defining arectangular outer periphery which substantially matches said secondrectangular periphery of the roof frame, said columns being set backwithin the corners of said the first rectangular periphery of the baseframe; d. a floor panel having an outer periphery substantially matchingsaid second periphery, said floor panel being dimensioned to rest oninner edge portions of the base beams; e. a roof panel for resting onthe roof frame and having an outer periphery at least as large in lengthand width as said first rectangular periphery; and f. side and end wallpanels dimensioned to fit between said base beams and said roof panelwith said wall panels resting on outer edge portions of said base beams,said wall panels enclosing outer peripheries both of said four columnsand of the roof frame.
 2. A modular building according to claim 1,wherein said base beams and roof beams are I beams.
 3. A modularbuilding according to claim 1, wherein said columns are I beams havingupper and lower end plates at their respective upper and lower ends,said end plates having apertures for bolting to apertures in the roofand base beams.
 4. A modular building according to claim 3, wherein saidlower end plates of the columns each have four rectangularly positionedbolt apertures, an outer three of said lower end plate apertures beingsuitable for bolting to apertures in the base beams at a respectivecorner, and wherein said base beams have a reinforcing corner elementattached to the inside of each corner, which reinforcing element has anadditional aperture positioned to be bolted to a fourth, inside,aperture of the lower end plate.
 5. A modular building according toclaim 4, wherein said reinforcing corner element for each corner of thebase component is in the form of a tube having sides welded to innersides of said base beams and having an upper end plate providing saidadditional aperture.
 6. A modular building according to claim 5, whereinsaid tubes extend down below lower surfaces of said base beams toprovide legs for supporting the building.
 7. A modular buildingaccording to claim 1, wherein said roof frame has apertured lifting lugsfixed to its top surface, each lifting lug being positioned above one ofsaid columns, wherein said roof panel is apertured to accommodate saidlifting lugs.
 8. A modular building according to claim 2, wherein saidroof beams each have, attached thereto, an additional elongated roofmember which provides flanges at said second rectangular periphery,which flanges provide locating means for the side and end wall panels.9. A modular building according to claim 8, wherein said additionalelongated roof members are channel members fixed to lower surfaces ofsaid roof beams.
 10. A modular building according to claim 2, whereinsaid base beams each have, attached thereto, an additional elongatedbase member having a flange suitable for locating the outer periphery ofsaid floor panel.
 11. A modular building according to claim 1, whereinsaid base frame and said roof frame each have one or more additional,intermediate lateral members which meet said longitudinal members atintermediate, reinforced areas, and wherein said intermediate areas ofthe base and roof frames are connectable by additional columns whichhave bolt connections to said base and roof beams.
 12. A modularbuilding according to claim 1, wherein said base frame has one or moreadditional longitudinal beams fixed at their ends to said lateral basebeams.
 13. A modular building according to claim 1, wherein said roofframe has one or more additional longitudinal beams fixed at their endsto said lateral roof beams.